United States Patent [191

[11]
[45]

Willbanks

Henry 0. Willbanks, Cookeville,

[51]

1m. 01.5 ............................................. .. HOSB 3/10

[52]

US. 0. ................................. ..219/s44;219/s41;

338/274
[58]

Field of Search .............. .. 219/541, 544; 338/238,

[56]

338/239, 240, 241, 274, 275; 29/611, 614

References Cited
U.S. PATENT DOCUMENTS
Lindskog et al. ................. .. 219/544
Naruo et a1. ...................... .. 338/238

FOREIGN PATENT DOCUMENTS

0136738 11/1978

ABSTRACT

An electric heating device is disclosed which comprises

a generally tubular sheath, an elongated coil of electri

cal resistance heating wire passing through a portion of

the sheath, and a metal terminal at each end of the
sheath. The interior of the sheath is ?lled with a granu

lar heat conducting, electrically insulating material, and

the sheath is sealed at at least one end with a thermo

plastic material having a melting temperature in the

range of the temperature of the terminal when the heat

ing device is in heated condition. The thermoplastic

material must be substantially permeable to gases while
melted and substantially impermeable to gases while
solid. The use of such a seal enables the heating element
to consume oxygen in a normal manner while hot, but

will prevent the entry of moisture into the element

while the element is cool and the seal is in a solid condi
tion.

Japan ................................... .. 29/611

Primary Examiner-Bruce A. Reynolds

)1
11 11

& Scheiner

[57]

[73] Assignee: Teledyne Ind. Inc., Cookeville, Tenn.

[21] Appl. No.: 583,248
[22] Filed:
Sep. 17, 1990

3/1983
4/1986

Nov. 19, 1991

Attorney, Agent, or Firm-Dennison, Meserole, Pollack

Tenn.

4,376,245
4,586,020

5,066,852

Assistant ExaminerMichael D. Switzer

[54] THERMOPLASTIC END SEAL FOR

ELECTRIC HEATING ELEMENTS

[75] Inventor:

Patent Number:
Date of Patent:

11 Claims, 1 Drawing Sheet

US. Patent

Nov. 19, 1991

5,066,852

1Figure

\I 11
k

5,066,852

such heating elements. To form breathing end seals, a

thermosetting silicone ?uid is applied to the sheath

THERMOPLASTIC END SEAL FOR ELECTRIC

HEATING ELEMENTS

ends, and allowed to wick into the element. When a

wick depth of 1 to 3 inches occurs, heat is applied to

BACKGROUND OF THE INVENTION
The present invention relates to tubular electric heat

5 make the ?uid gel. The silicone seals are permeable to

ing elements.
Tubular electric heating elements are commonly used
in domestic appliances such as ovens, ranges, toasters
and broilers but also have a wide variety of industrial In.

applications.
The tubular heating element is formed of a generally
tubular metal sheath serving as the casing. The gener
ally tubular sheath can have any one of a variety of

cross-sectional shapes, including circular, oval, rectan

gular, hexagonal, etc. A resistance wire, wound to a
given diameter and ?tted with a terminal at each end,

makes up the helix assembly or working part of the

heating element. The helix assembly lies at the core of
the sheath and runs its length, with the terminals ex
tending past the ends of the sheath to provide for elec
trical connections. A powder, typically magnesium

air, and allow normal oxidation to take place within the

sheath.
While breathing seals do allow air to pass through to

the inside of the sheath at high temperatures, they also

allow water vapor to pass through to the inside of the
sheath at low temperatures. Without routine operation,

elements with breathing seals accumulate high levels of

moisture and exhibit proportionally high current leak
age between the heating element and the sheath. Thus,
both hermetic and breathing seals have serious disad
vantages when utilized in heating elements designed to
operate at temperatures over 1000 F.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to
provide a heating element which can operate at high
temperatures without the disadvantages of the prior art.

oxide, ?lls the space between the helix and the inside

It is a further object of the invention to provide a

wall of the tube to serve as an electrical insulator and

heating element having a seal which is substantially

hermetic at low temperatures but which is permeable to

heat conductor. Heating elements properly annealed

can be formed to the desired shape.

In general, tubular electric heating elements may be

operated at temperatures to about two thousand degrees
Fahrenheit. While the coil of resistance wire may reach
a very high temperature, the terminal at each end re
mains relatively cool and is therefore known as a cold

pin. The terminals passing through the ends of the

heating element typically remain in a temperature range
of 150 to 200 F.
Seals are necessary at each end of the tubular heating
element. The seals serve as an electrical insulator be

tween the sheath and the terminal and retard or prevent

the entrance of water into the heating element. Resin

bushings have been used as end seals, such as in US.

Pat. No. 4,182,948, but better sealing has been obtained

with end seals formed in-situ from glass, ceramics and
polymers. These formed in-situ seals can be hermetic
seals or breathing seals.
Hermetic seals serve as a substantially impervious
barrier to entry of gases and liquids at each end of the
heating element, and have been formed of glass or a
ceramic in the prior art, for example, in US Pat. Nos.

3,195,093, 4,034,330, and 4,506,251. In addition, epoxy

materials are known for use as hermetic seals, as they
are thermosetting and cure to heat resistant and substan

oxygen at the operating temperature of the element.

In order to achieve these and other objects of the
invention, an electric heating device is provided com

prising:
a generally tubular sheath;
an elongated coil of electrical resistance heating wire

passing through a portion of the sheath and spaced

therefrom;
an elongated ?rst metal terminal arranged at one end

of the sheath, one end of the ?rst terminal being electri

cally connected to one end of the wire at the interior of
the sheath and spaced therefrom, the other end of the
?rst terminal being exposed at the exterior of the sheath;
an elongated second metal terminal arranged at the
other end of the sheath, one end of the second terminal
being electrically connected to the other end of the wire
at the interior of the sheath and spaced therefrom, the
other end of the second terminal being disposed at the

exterior of the sheath;

a mass of granular, heat conducting, electrically insu
lating material disposed within the sheath and embed
ding the wire and terminals and retaining the wire and
terminals in spaced relation with the sheath;

tially impervious materials.

a seal disposed at least one end of the sheath between

the terminal and the sheath, the seal formed of a ther

Hermetic seals, however, present a problem when

used with elements having an operating temperature of

range of the temperature of the terminal when the heat

1000 F. or more. Elements operating at these high

temperatures consume oxygen inside the sheath by oxi
dation of the sheath and the wire. Once the existing
supply of oxygen within the sheath is exhausted, addi

tional oxygen consumption may take place by break

down of the insulating material. As reported in US. Pat.

moplastic material having a melting temperature in the

ing device is in heated condition, the thermoplastic
material being substantially permeable to gases while
melted and substantially impermeable to gases while
solid.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole drawing Figure is a cross-section of a heat

No. 3,195,093, it is possible that a vacuum will be 60

ing element according to the invention.
formed within the sheath, leading to a decrease in the

thermal conductivity of the insulating material and a

commensurate increase in the temperature of the wire,
resulting in vaporization and failure of the resistance
65
wire after a relatively short time.
In order to avoid the problems inherent in the use of

hermetic seals with high temperature heating elements,

it is also known to utilize breathing end seals with

DETAILED DESCRIPTION OF THE

INVENTION

Shown in the drawing Figure is a typical tubular

electrical heating device, generally designated as 10.
The heating device includes a metal sheath 12, formed
of a metal which is resistant to high temperatures such

5,066,852

as Incoloy , a nickel chromium steel comprising about

30% by weight nickel and 20% by weight chromium.

Humidity Test

Other stainless-type steels may also be used as the

sheath, as well as cobalt type steels, copper, and alumi

two rods prepared with silicone were placed in a hu

num.

Passing through the sheath is a coil 14 of wire, typi

cally Nichrome wire (80 Ni-20 Cr) which is heated to
a high temperature when an electrical current is passed

through it.
A compacted insulating powder 16, such as magne
sium oxide powder, is disposed within the sheath em
bedding the coil of wire and serving to separate the coil
of wire from the sheath. Attached to each end of the
sheath is a terminal 18, a .cold pin, which may be
formed of a mild steel plated with nickel and rolled. The

Ten rods prepared according to the invention and

midity chamber at 90% relative humidity and 95 F. for

60 days. Each day resistance readings were taken on the
test rods to determine moisture in?ltration, with some

moisture in?ltration being indicated on all rods during

the test period. After 60 days, the rods were removed
and subjected to Underwriters Laboratories hot resis
tance and hot leakage tests, in which a voltage of 1250
volts AC is connected between the case and the termi
nal of the element, and resistance and current are mea
sured therebetween. A passing rod has a resistance

greater than 0.060 megohms and a leakage current of

steel or a stainless steel.

less than 25 milliamperes.

The only failure among the 12 rods, was in a single

In the operation of the typical heating element shown

in the Figure, the coil of Nichrome @ wire will achieve

wax sealed rod which failed due to a puncture in the

sheath and not due to a failure of the seal.

a temperature of about 1800 F., while the outside of the

sheath will attain a temperature of about 1500 F. The

The remaining wax-sealed rods had hot resistances

between 2 and 0.2 megohms, averaging 0.87 megohms.

terminal 18 does not attain these high temperatures, but

The two silicone sealed rods had resistances of 0.8 and

cold pin may also be formed of an unplated, rolled mild

rather remains at a temperature of about 185 F. as it

0.4 megohms, averaging 0.6 megohms.

The humidity test showed that the wax seal was able
passes through the ends of the sheath.
25
to provide an effective barrier to moisture contamina
The end seal 20 of heating element 10 is formed of

microcrystalline wax. Microcrystalline wax has been

found to be the ideal thermoplastic material for utiliza

tion in the heating elements of the invention, as it has a

melting point in the range of 130 to 200 F. At 185 F., 30

the microcrystalline wax exists in a viscous, substan
tially liquid state in which it is permeable to gases but
does not run out of the sheath. While microcrystalline
wax is the ideal material for use as these end seals, other
waxes and polymers may be utilized as well, as long as 35

tion, and was comparable to the silicone seal.

THERMAL ENDURANCE TESTING

Six rods with wax seals were subjected to a 1000

cycle test as set forth by Underwriters Laboratories. At

the completion of the test, the rods were subjected to
Underwriters Laboratories hot resistance and leakage
tests. All rods passed both tests.
Four wax sealed rods were connected to a test board

they are substantially liquid at the temperature of the

terminal while the heater is in operation, permeable to
gases in their liquid state, impermeable in the solid state,
and stable and retainable within the sheath.
Resins which melt in the proper range include ( acet
amide (mp l7ll78 F.) and acrylic resins such as vinyl
acrylic acid (mp 170 F.). Other waxes include Bees
wax, Candelilla wax, Carnauba wax, Japan wax, paraf

and subjected to 1000 hours continuous operation. After

the completion of the test, Underwriters Laboratories
hot leakage and resistance tests were performed. All
elements passed both tests.

A series of test rods was prepared in various diame

ters of 0.260 and 0.312 inches. The rods were formed

MIGRATION TEST

rome heating element, cold pins formed of mild steel

when hot, tends to be in?uenced such that the thermo

An accelerated life test was conducted on 12 wax

sealed rods, six bake and six broil. The accelerated life
test procedure consists of a total of 45 days operation in
three stages, at the rated voltage, at 277 volts and at 300
volts. This test simulates 20 years of element use. At the
?n wax, and mineral wax, as well as waxy materials
45 end of the simulation, the rods were subjected to Under
such as soybean lecithin (mp 150 F.).
writers Laboratories hot leakage and hot resistance tests
and all rods passed the tests.
EXAMPLES

When a heating element is energized and cooled, air

50
with a sheath of Incoloy stainless steel, a Nich
is expelled and drawn in, respectively. The sealant, ?uid

plated with nickel and rolled, and magnesium oxide

plastic material is pushed outwardly when air is ex

insulation. The rods were assembled and annealed at a

pelled and drawn inwardly as the rod cools. In the
temperature of 2000 F. As the annealed rods were 55 heating cycle, the wax does not leave the rod but con
assumed to be moisture free, they were sealed as soon as
centrates at its ends. However, upon cooling, if the

they were removed from the annealing furnace.

The rods according to the invention were sealed by

sealant migrates into the hot area this may cause a fail
ure of the element.

dipping the ends of the rods in molten wax maintained

At the conclusion of the thermal test described

at a temperature of approximately 230 F. The wax used 60 above, the rods tested were cut open to examine migra
was BE Square 195 Amber produced by Boler Petro
tion of the sealant. Observations revealed the maximum
leum Company, a food safe, biodegradable, thermoplas
migration was only one inch. This depth is a consider

tic material containing no hazardous materials. Dip time

able distance from the heat zone of the rods and there
fore it is considered that there is little danger that the
and sheath were brushed to remove the coat of wax.
65 sealant will migrate into the heating area.
Comparative rods were sealed in the normal manner,
What is claimed is:
utilizing a silicone varnish known as 1-2577 conformal
1. An electric heating device comprising:
coating manufactured by Dow Corning.
a generally tubular sheath;
was two minutes for each end. After dipping, the pin

5,066,852

an elongated coil of electrical resistance heating wire

passing through a portion of said sheath and spaced

meable to gases while solid.

2. An electric heating device according to claim 1,

wherein said thermoplastic material comprises wax.
3. An electric heating device according to claim 2,

therefrom;
an elongated ?rst metal terminal arranged at one end
of said sheath, one end of said ?rst terminal being
electrically connected to one end of said wire at the

wherein said wax is a microcrystalline wax.

4. An electric heating device according to claim 1,

wherein said thermoplastic material has a melting tem
perature in the range of 130 to 190 F.
5. An electric heating device according to claim 1,
wherein said generally tubular sheath is formed of
metal.
6. An electric heating device according to claim 5,
wherein said metal sheath is stainless steel.
7. An electric heating device according to claim 1,
wherein said elongated coil is formed of Nichrome

interior of said sheath and spaced therefrom, the

other end of said ?rst terminal being disposed at the
exterior of said sheath;
an elongated second metal terminal arranged at the
other end of said sheath, one end of said second

terminal being electrically connected to the other

end of said wire at the interior of said sheath and

spaced therefrom, theother end of said second

terminal being disposed at the exterior of said

sheath;

wire.

a mass of granular, heat conducting, electrically insu

8. An electric heating device according to claim 1,

lating material disposed within said sheath and

embedding said wire and said terminals and retain

wherein said insulating material comprises magnesium

oxide.
9, An electric heating device according to claim 1,

ing said wire and said terminals in spaced relation

with said sheath;

wherein a said seal is disposed at both ends of said

sheath.

:1 seal disposed at least one end of said sheath between

said terminal and said sheath, said seal formed of a

thermoplastic material having a melting tempera

6
ble to gases while melted, and substantially imper

10. An electric heating device according to claim 1,

25 which is a broiling element.

ture in the range of the temperature of the terminal

when the heating device is in heated condition, said

11. An electric heating device according to claim 1,

which is an oven heating element.

thermoplastic material being substantially permea

35

45

50

55

65

it